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Steady State Disc Rim and Blade Root Stress The two highly stressed areas of the IBR are disc rim and the root of the blade. A series of sensitivity studies was performed to reduce rim and blade root stress. The rim stress is mainly caused by the uneven radial deflections at the leading edge and the trailing edge of the rim. The blade was joined with the disc and a root fillet radius was added. The radial stress in the base of the blade was found to be unevenly distributed. The rotor was reshaped and re-optimized to reduce and balance rim deflection (Figure 6). The blade was then stacked so the center of gravity of the blade cross sections lay on a radial line. (a) (b) Figure 6: Plot of disc deflection for (a) original and (b) modified disc designs The peak radial root stress was reduced by approximately 5 ksi. The high blade root radial stress was not entirely eliminated because untwisting of the blade causes some of the radial root stress variation. Figure 7 is a plot of the maximum principal stress in the rotor stress in the root of the blade. using this data. The results were examined for thermal transients that may cause locally high stress. Cold Start Up This analysis for cold start-up was performed for 100 seconds of operation, assuming that all the hardware has an initial temperature of –10°F. One concern was that the blades would become hot quickly while attached to a rotor hub that was still low in temperature, leading to high thermal stresses. The start up simulated is from a stationary rotor to idle. The final rotor rpm is 50% of max power and the idle blade sink temperature is approximately 1200°F lower than the temperature at maximum power. Figure 8 shows a plot of rotor maximum principle stress as a function of start up time. 35000 30000 25000 20000 15000 10000 5000 0 Rotor Maximum Principal Stress . 0 20 40 60 80 100 120 Time (sec) 5 Figure 8: Cold start-up rotor maximum principal stress as a function of time Emergency Trip Shut Down In this analysis the rotor is operating at full power at the start of the simulation. The initial blade mid-span sink temperature is 1902°F and the initial rotor speed is 50,352 rpm, which represent the highest stress state. The stress diminishes as the rotational speed decreases and the thermal gradients are reduced. Figure 9 is a plot of maximum principle stress as a function of time. The start-up and shut down analysis suggests that the transient stresses are lower that what are expected at full power conditions. 5 50 4 4 4 a a a 0 0, 7 7 7 t t t t t , ,9 , , ta a a 9 96 ,5 5 c c c 6 6 50 0 0 h h h 0 0 0 b 0 0 0 a m m m b b a a e e o o o n n n en n n r r r d d d 4 t t e e es tf 4 4 f f s s i i t t tr 7 7 7 il l ll l r r , , , le e e e 4 4 4 e e t t t s s s ss 0 0 0 s s 0 0 0 s s t t tr r r e e e s s s s s s Figure 7: Plot of IBR stress after shape optimization Significant hoop stress was also found in the blade root fillet. A series of studies were performed to gain an understanding into the cause of the root fillet stress and these studies have not been concluded. Aero-thermal transient analysis data for convective heat transfer coefficients, blade sink temperature at tip, mid-span and root, and rotational velocity were provided as a function of time. Transient structural analyses of the IBR design were performed 109 Copyright © 2004 by ASME Stress (psi)PDF Image | ADVANCED MICROTURBINE SYSTEMS Final Report for Tasks 1 Through 4 and Task 6
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